Extended functionality sleep manager module for electric vehicles, related systems and methods

ABSTRACT

The present invention is generally directed to a Sleep Manager Module (“SLM”). In one case, the present invention provides a stand-alone Sleep Manager Module. The Sleep Manager Module is capable of optimizing electric vehicle power consumption based on external temperature. It has one or more interfaces that are electrically connected to a microcontroller. The microcontroller is operably connected to memory, and the one or more interfaces is selected from a group of interfaces consisting of a fast charge connector, a level II Electric Vehicle Supply Equipment, and temperature/battery voltage sensors. The microcontroller is connected to a Vehicle Integration Manager through a Wake-Up line and Vehicle Communication Line.

FIELD OF THE INVENTION

The present invention is generally directed to a Sleep Manager Module(“SLM”).

BACKGROUND OF THE INVENTION

There have been reports regarding modules that manage power inelectronic devices and methods related to the modules. For instance,U.S. Pat. No. 9,630,514, entitled “System And Method For Vehicle PowerManagement” is allegedly directed to the following: “A power managementsystem for a vehicle having wheels and an electric machine operable toprovide torque to drive at least one of the wheels includes a firstenergy storage system capable of supplying power to operate the electricmachine. The system also includes a second energy storage system capableof supplying power directly to at least one vehicle load at a lowervoltage than the first energy storage system. A voltage conversiondevice is operable to reduce a voltage of the power supplied by thefirst energy storage system to the lower voltage to charge the secondenergy storage system when the vehicle is in a key-off state.” Abstract.

U.S. Pat. No. 9,610,857, entitled “Power Management In ElectricVehicles” is allegedly directed to the following: “Various techniquesdescribed herein relate to electric vehicle power management system formanaging a plurality of battery modules in a battery pack. Such electricvehicle power management system may include a plurality of batterymanagement systems corresponding to a plurality of battery modules, andan energy management system for managing the plurality of batterymanagement systems. The energy management system and the plurality ofbattery management systems may adopt master-slave wirelesscommunication, and may use a single wireless frequency channel or aplurality of assigned wireless frequency channels.” Abstract.

U.S. Pat. No. 8,269,641, entitled “Vehicle Power Management System” isallegedly directed to the following: “A vehicle power management system(VPMS) controls a charging voltage of a battery in a vehicle, wherein aVPMS controller evaluates state-of-charge (SOC), battery temperature,and battery charging current to determine a charge mode. A rapid chargemode is used when the SOC is less than a first threshold, wherein theVPMS controller selects a target rapid charge voltage, compensates thetarget rapid charge voltage for the battery temperature, and transmitsthe compensated rapid charge voltage to the charging source. A normalcharge mode is used when the SOC is greater than the first threshold andless than a second threshold, wherein a target normal charge voltage isselected and compensated which is less than the target rapid chargevoltage. A trickle charge mode is used when the SOC is greater than thesecond threshold, wherein a target trickle charge voltage is less thanthe target normal charge voltage. The VPMS controller also enters thetrickle charge mode in the event of a failure to receive the SOC,battery temperature, or battery charging current from a batterymonitor.” Abstract.

Despite the various reports regarding modules that manage power inelectronic devices and related methods, there is still a need for novelmodules and related methods.

SUMMARY OF THE INVENTION

In one case, the present invention provides a stand-alone sleep ManagerModule that could optimize electric vehicle power consumption based onexternal temperature.

In another case, the present invention provides a stand-alone SleepManager Module that could optimize electric vehicle power consumptionbased on the low voltage battery power status.

In another case, the present invention provides a stand-alone SleepManager Module that could optimize utilization of Electric Vehiclechargers based on external temperature.

In another case, the present invention provides a stand-alone SleepManager Module that could optimize utilization of Electric Vehiclechargers based on the low voltage battery power status.

In another case, the present invention provides a business method. Thisbusiness method involves selling the Sleep Manager Module as anindependent unit to be used by any Electric Vehicle.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows an electronic system for an electric vehicle including aSleep Manager Module according to the present invention.

FIG. 2 shows a Sleep Manager Module according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

“Battery Management System”, or “BMS”, refers to an electronic systemthat manages a rechargeable battery (cell or battery pack). Nonlimitingexamples of management functions that a BMS can carry out include:protecting the battery from operating outside of its safe operatingarea; monitoring the battery's state; calculating secondary data for thebattery and reporting it; controlling the battery's environment;authenticating the battery; and, balancing the battery.

“CHAdeMO” refers to a trade name of a quick charging method for batteryelectric vehicles delivering up to 62.5 kW of direct current (500 V, 125A) via a special electrical connector.

“CCAN” refers to Charger Control Area Network”.

“Controller Area Network”, or “CAN”, refers to a robust vehicle busstandard designed to allow microcontrollers and devices to communicatewith each other in applications without a host computer.

“DC-PDU” refers to Direct Current-Power Distribution Unit. The PowerDistribution Unit, or “PDU”, provides safe distribution of high voltageelectric vehicle and hybrid electric vehicle applications.

“HV Battery” refers to a high voltage battery.

“Ignition Switch”, or “Starter Switch”, refers to a switch in thecontrol system of a vehicle that activates the low voltage electricalsystems for the vehicle.

“Inverter” refers to an electronic device or circuitry that changesdirect current (“DC”) to alternating current (“AC”).

“LV Battery” refers to a low voltage battery.

“SAE J1772” refers to a North American standard for electricalconnectors for electric vehicles maintained by the SAE International andhas the formal title “SAE Surface Vehicle Recommended Practice J1772,SAE Electric Vehicle Conductive Charge Coupler”. It covers the generalphysical, electrical, communication protocol and performancerequirements for the electric vehicle conductive charge system andcoupler.

“Sleep Manager Module”, or “SLM”, refers to a module that optimizesenergy consumption while monitoring both temperatures and voltages. TheSLM is connected to the main Vehicle Control Area Network (VCAN) and tothe dedicated Charger Control Area Network (CCAN), waking up the vehicleintegration management unit (VIM) when certain conditions occur.

“Subsystem” refers to a self-contained system within a larger system.

“Vehicle” refers to a mobile machine that transports people or cargo.Typical vehicles include wagons, bicycles, motor vehicles (e.g., buses,cars, motorcycles, trucks), railed vehicles (trains, trams), watercraft(ships, boats), aircraft and spacecraft.

“VCAN” refers to Vehicle Control Area Network.

“VIM” refers to Vehicle Interface Module.

An electric vehicle's utilization can be optimized by ensuring that allsubsystems are in a readiness state. To that effect, a variety ofexternal and internal vehicle conditions can be monitored leading theVehicle Control Module to take appropriate actions.

A Sleep Manager Module (SLM) optimizes energy consumption whilemonitoring both temperatures and voltages. The SLM is connected to themain Vehicle Control Area Network (VCAN) and to the dedicated ChargerControl Area Network (CCAN), waking up the vehicle integrationmanagement unit (VIM) when certain conditions occur.

This independent controller activates electronic systems under certainconditions. The systems that can be activated include the batteryheating and cooling module, the DC Power Distribution Unit and theVehicle Interface module. The conditions triggering the activationinclude external temperatures, voltage setting or set schedule.

The SLM is a standalone electronics control device capable ofcommunicating with the rest of the vehicle on the Controlled AreaNetwork (CAN). The Module is powered with available vehicle DC voltageand provides interfaces for both ambient temperature sensor and vehiclelow voltage measurement. The controller includes an ON/OFF schedulerwhich can be modified through calibration. Thresholds for bothtemperature and voltage controls can also be changed via calibration.

FIG. 1 shows an electronic system for an electric vehicle including aSleep Manager Module according to the present invention. The DC FastCharger is electrically connected to the Direct Current-PowerDistribution Unit (“DC-PDU”), the Sleep Manager Module (“SLM”) and theHigh Voltage Battery (“HV Battery”). J1772 signals are provided to theSLM by the AC Charger. In addition to the DC Fast Charger, the DC-PDU iselectrically connected to the SLM, which is electrically connected tothe Low Voltage Battery (“LV Battery”), the Battery Management System(“BMS”) of the HV Battery and the Vehicle Interface Module (“VIM”).

FIG. 2 shows a Sleep Manager Module according to the present invention.As shown, the SLM has three interfaces that are electrically connectedto a microcontroller. The microcontroller is operably connected tomemory, which stores programmable functions. A fast charge connector isdepicted as being electrically connected to the top SLM interface. Themiddle SLM interface is shown as being electrically connected to a levelII Electric Vehicle Supply Equipment. Temperature and battery voltagesensors feed into the bottom SLM interface. A Wake-Up line and VehicleCommunication Line (CAN) connect the SLM's microcontroller to theVehicle Integration Manager (“VIM”).

In one case, the present invention provides a stand-alone Sleep ManagerModule that could optimize electric vehicle power consumption based onexternal temperature. The SLM has one or more interfaces that areelectrically connected to a microcontroller, which is operably connectedto memory. The one or more interfaces provide electrical connection toone or more of the following elements: a fast charge connector; level IIElectric Vehicle Supply Equipment; temperature/battery voltage sensors.Connection from the microcontroller to a Vehicle Integration Manageroccurs through a Wake-Up line and Vehicle Communication Line.

In another case, the present invention provides a stand-alone SleepManager Module that could optimize electric vehicle power consumptionbased on the low voltage battery power status. The SLM has one or moreinterfaces that are electrically connected to a microcontroller, whichis operably connected to memory. The one or more interfaces provideelectrical connection to at least the following element: a batteryvoltage sensor. Connection from the microcontroller to a VehicleIntegration Manager occurs through a Wake-Up line and VehicleCommunication Line.

In another case, the present invention provides a stand-alone SleepManager Module that could optimize utilization of Electric Vehiclechargers based on external temperature. The SLM has one or moreinterfaces that are electrically connected to a microcontroller, whichis operably connected to memory. The one or more interfaces provideelectrical connection to at least the following element: a temperaturesensor. Connection from the microcontroller to a Vehicle IntegrationManager occurs through a Wake-Up line and Vehicle Communication Line.

In another case, the present invention provides a stand-alone SleepManager Module that could optimize utilization of Electric Vehiclechargers based on the low voltage battery power status. The SLM has oneor more interfaces that are electrically connected to a microcontroller,which is operably connected to memory. The one or more interfacesprovide electrical connection to at least the following element: abattery voltage sensor. Connection from the microcontroller to a VehicleIntegration Manager occurs through a Wake-Up line and VehicleCommunication Line.

In another case, the present invention provides a business method. Thisbusiness method involves selling the Sleep Manager Module as anindependent unit to be used by any Electric Vehicle. The SLM has one ormore interfaces that are electrically connected to a microcontroller,which is operably connected to memory. The one or more interfacesprovide electrical connection to one or more of the following elements:a fast charge connector; level II Electric Vehicle Supply Equipment;temperature/battery voltage sensors. Connection from the microcontrollerto a Vehicle Integration Manager occurs through a Wake-Up line andVehicle Communication Line.

1. A stand-alone Sleep Manager Module, wherein the Sleep Manager Moduleis capable of optimizing electric vehicle power consumption based onexternal temperature, wherein the Sleep Manager Module has one or moreinterfaces that are electrically connected to a microcontroller, andwherein the microcontroller is operably connected to memory, and whereinthe one or more interfaces is selected from a group of interfacesconsisting of a fast charge connector, a level II Electric VehicleSupply Equipment, and temperature/battery voltage sensors, and whereinthe microcontroller is connected to a Vehicle Integration Managerthrough a Wake-Up line and Vehicle Communication Line.
 2. Thestand-alone Sleep Manager Module according to claim 1, wherein the SleepManager Module comprises a battery voltage sensor interface, and whereinthe Sleep Manager Module is capable of optimizing electric vehicle powerconsumption based on low voltage battery power status.
 3. Thestand-alone Sleep Manager Module according to claim 1, wherein the SleepManager Module comprises a temperature sensor interface, and wherein theSleep Manager Module is capable of optimizing utilization of electricvehicle chargers based on external temperature.
 4. The stand-alone SleepManager Module according to claim 1, wherein the Sleep Manager Modulecomprises a battery voltage sensor interface, and wherein the SleepManager Module is capable of optimizing utilization of electric vehiclechargers based on the low voltage battery power status.
 5. A businessmethod, wherein the business method comprises selling a Sleep ManagerModule as an independent unit to be used by any electric vehicle,wherein the Sleep Manager Module is capable of optimizing electricvehicle power consumption based on external temperature, wherein theSleep Manager Module has one or more interfaces that are electricallyconnected to a microcontroller, and wherein the microcontroller isoperably connected to memory, and wherein the one or more interfaces isselected from a group of interfaces consisting of a fast chargeconnector, a level II Electric Vehicle Supply Equipment, andtemperature/battery voltage sensors, and wherein the microcontroller isconnected to a Vehicle Integration Manager through a Wake-Up line andVehicle Communication Line.
 6. The business method according to claim 5,wherein the Sleep Manager Module comprises a battery voltage sensorinterface, and wherein the Sleep Manager Module is capable of optimizingelectric vehicle power consumption based on low voltage battery powerstatus.
 7. The business method according to claim 5, wherein the SleepManager Module comprises a temperature sensor interface, and wherein theSleep Manager Module is capable of optimizing utilization of electricvehicle chargers based on external temperature.
 8. The business methodaccording to claim 5, wherein the Sleep Manager Module comprises abattery voltage sensor interface, and wherein the Sleep Manager Moduleis capable of optimizing utilization of electric vehicle chargers basedon the low voltage battery power status.